3 & 4 Borehole Product Rangegatorpumps.co.za/wp-content/uploads/2018/11/A-34-Borehole-Pump-Range-2018.pdfconnection to motor and discharge pipe. Offers resistance to corrosion and

3” & 4” Borehole Product Range

MARCH 2018

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INDEX

3 SD BOREHOLE RANGE (3”)......................................................... 4 3 SD 1.8...................................................................................... 5 3 SD PERFORMANCE DATA.................................................. 6 3 SD TECHNICAL DATA......................................................... 7 MA CONTROL BOX SINGLE PHASE................................... 8 M521 DIGITAL CONTROL BOX SINGLE PHASE............... 9 4 ST BOREHOLE RANGE (4”)....................................................... 12 4ST 1 PERFORMANCE DATA.............................................. 14 4ST 1 TECHNICAL DATA..................................................... 15 4 SD BOREHOLE RANGE (4”)......................................................... 16 4 SD 2........................................................................................ 18 4 SD 3........................................................................................ 19 4 SD 4........................................................................................ 20 4 SD 6........................................................................................ 21 4 SD 8........................................................................................ 22 4 SD 10...................................................................................... 23 4 SD 12...................................................................................... 24 4 SD 16....................................................................................... 25 4 SD DIMENSIONS & WEIGHTS........................................... 26 4 SD TECHNICAL DATA......................................................... 29 4” OIL FILLED MOTOR SINGLE PHASE............................. 30 SINGLE PHASE CONTROLLERS.......................................... 31 M521 DIGITAL CONTROL BOX SINGLE PHASE............... 32 4” OIL FILLED MOTOR THREE PHASE............................... 34 THREE PHASE CONTROLLERS DIGITAL 0.37 - 7.5KW.... 38 THREE PHASE CONTROLLER DIGITAL 0.37 - 5.5 GEN2.. 47 4” OIL FILLED MOTOR 220V THREE PHASE..................... 64 This document contains hyperlinks. If you are using the electronic PDF copy you do not need to go through the entire document to get to the required page, you can s imply c l i ck on the r equ i r ed page on your index page . C l i c k o n t h e t o p G a t o r l o g o t o r e t u r n t o t h e I n d e x p a g e .

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3 SDM BOREHOLE RANGE (3”)


3 SDM BOREHOLE RANGE (3”)

3SDMApplications For water supply from boreholes, wells or reservoirs Continues duty rated products for use in domestic, farming and irrigation applications. Operating Conditions Maximum fluid temperature up to + 35 ° C Maximum sand content: 0.25% Minimum well diameter: 3” Motor and Pump Replaceable Pump and Motor. Single-Phase: 220 - 240V/50Hz Equipped with start control box or digital auto-control box. Curve tolerance according to ISO 9906 Warranty: 1 year (according to our general sales conditions)


3 SDM 1.8

VERSION MODEL P2CAP

μf

DELIVERY

1* 2**3 ~

380-415VkW HP

m3/h 0 0.3 0.6 0.9 1.2 1.5 1.8 2.1 2.4 2.7

l/min 0 5 10 15 20 25 30 35 40 45

√ √ 3SDM2/8 0.18 0.25 16

Head (m)

35 34 34 33 32 29 26 22 17 11√ √ 3SDM2/11 0.25 0.39 16 48 47 47 46 44 40 36 30 24 15√ √ 3SDM2/15 0.37 0.5 20 65 64 64 63 60 55 49 41 33 21√ √ 3SDM2/21 0.55 0.75 25 91 90 90 88 84 77 68 58 46 29√ √ 3SDM2/27 0.75 1 35 117 116 115 113 107 99 88 75 59 38√ 3SDM2/33 1.1 1.5 45 143 142 141 138 131 121 107 91 72 46√ 3SDM2/39 1.1 1.5 45 168 168 167 163 155 143 127 108 85 55√ 3SDM2/47 1.5 2 55 203 202 201 196 187 172 153 130 102 66

PERFORMANCE DATA 50 Hz

3SD2

* Version 1 Pump, Motor & Control Box ** Version 2 Pump, Motor, Control Box, Base plate, Cable (lenght - refer pricelist), Jiont & Rope.

3SD2/47

3SD2/39

3SD2/33

3SD2/27

3SD2/21

3SD2/15

3SD2/11

3SD2/8


TECHNICAL DATA

MAXIMUM CABLE LENGTH FROM PUMP TO STARTER

TYPE kW in(A) 1.5 mm2 2.5 mm2 4 mm2 6 mm2 10 mm2

220V~/50H

0.18 2.2 171 290

0.25 3.9 122 207

0.37 4.2 111 185 295

0.55 4.5 80 133 211 315

0.75 6 58 96 153 229 3771.1 9 48 79 153 190 316

1.5 10.3 34 57 92 137 228

INSTALLING A BOREHOLE PUMP AND MOTOR

MODELDN

DIMENSIONS(mm) WEIGHTS (kg)

1 ~220-240 P M T P M T

3 SDM 2/ 8 1 1/4” 377 288 665 1.8 4.0 5.83 SDM 2 / 11 1 1/4” 444 308 752 2.1 4.8 6.93 SDM 2 / 15 1 1/4” 535 338 873 2.4 5.6 8.03 SDM 2 / 21 1 1/4” 694 368 1062 3.2 6.4 9.63 SDM 2 / 27 1 1/4” 830 408 1238 3.5 7.5 11.03 SDM 2 / 33 1 1/4” 966 448 1414 4.3 8.7 13.03 SDM 2 / 39 1 1/4” 1101 493 1594 4.9 10.0 14.93 SDM 2 / 47 1 1/4” 1306 543 1849 5.8 11.3 17.1

DIMENSIONS AND WEIGHTS

SINGLE PHASE 3” OIL FILLED BOREHOLE MOTOR CAPACITOR RATINGS

kW Capacitor (mF) Running Amps

0.18 12

0.25 16

0.37 20

0.55 25

0.75 35

1.1 45

1.5 55

2.2 75


MA CONTROL BOX SINGLE PHASE

Technical dataThis single phase control box is equipped with a capacitor and thermal over-load protector.

Application rangeType of motor: Single phase motorMotor power: 0.18-1.5kWVoltage: 220V ~240VFrequency: 50Hz

Product functionsProvides basic protection against short circuiting and over current.

Operating methodManual control.

Installation environment indexGrade protection: IP44Environment temperature: -25oC to +55oCEnvironment humidity: (20-90)%RH

PUMP CONTROLLER

POWERRUNNING

CAPACITORMCB

kW HP Microfarad (µF) Amp

0.18 0.25 12 80.25 0.39 16 80.37 0.50 20 80.55 0.75 30 10

0.75 1.00 40 15

1.1 1.50 50 151.5 2.00 65 20


M521 DIGITAL CONTROL BOX SINGLE PHASEProduct functions • Liquid level control for supply (borehole) and delivery (storage). Enabled for operation, utilising floating level switch / liquid level probe / pressure switch. • Over / under voltage protection with adjustable parameters. • Auto / Manual operation. • Dynamic and interactive LCD display. • Push Button Calibration • Pump Accumulative Running Time Display • Pump Last Five Fault condition Recording • Controller enabled for operation with single phase motor fitted with internal or external capacitor from 0.37 to 1.5kw. Capacitor to be retro fitted for borehole motor use. Refer to capacitor size requirement as per table below.

Application rangeType of motor: Single phase motorMotor power: 0.37-2.2kWVoltage: 220VFrequency: 50Hz

Installation environment indexGrade protection: IP22Environment temperature: -25 ° C to + 55 ° CEnvironment humidity: (20-90)%RH

TECHNICAL DATA

RATED OUTPUT POWER 0.18kW - 1.5kWRATED INPUT VOLTAGE AC220V/50Hz Single PhaseTRIP RESPONSE TIME OF OVER LOAD 5sec - 5minTRIP RESPONSE TIME OF SHORT CIRCUIT 0.1secTRIP RESPONSE TIME OF UNDER / OVER VOLTAGE 5secTRIP RESPONSE TIME OF DRY RUN 6secRECOVERY TIME OF OVER LOAD 30minRECOVERY TIME OF UNDER / OVER VOLTAGE 5minRECOVERY TIME OF DRY RUN 30minTRIP VOLTAGE OF OVER VOLTAGE 110% of rated input voltageTRIP VOLTAGE OF UNDER VOLTAGE 80 of rated input volgage

SINGLE PHASE 3” / 4” OIL FILLED BOREHOLE MOTOR CAPACITOR RATINGS

kW Capacitor (mF)

0.37 20

0.55 25

0.75 35

1.1 45

1.5 55


INSTALLATIONELECTRICAL CONNECTION TO THE POWER SUPPLY:

PROTECTION FUNCTIONS*Dry run *Over load *Transient surge *Under voltage *Over voltage *Pump stalled *Short circuit

MEANING OF THE ICONS SHOWN ON THE LCD

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4 ST BOREHOLE RANGE 4”


This Slimline submersible borehole pump is suitable for 4” or larger boreholes, wells or reservoirs Manufactured from corrosion & abrasion resistant materials. This range is manufactured to NEMA standard for submersible motors. Designed for flow rates up to 1.5m3/h and heads of up to 325 meters. Application Groundwater supply to reservoirs.Irrigation in horticulture and agriculture.Groundwater Lowering.Pressure boosting. Solar applications. Specification Capacity: up to 1.5m3/h at 2850rpm, 50Hz Head: up to 325m at 2850rpm, 50Hz Power: 0.37kW to 1.5kW Power Supply: Single-phase 220 ~ 240V Three-phase 380 ~ 415V 220v -3phase Water Temp: up to 35°C Solid Handeling: less than 0.02% Water PH: 6.5-8.0 Construction characteristics Abrasion-resistant construction. The front wear plate, combined with the floating impellers, ensure optimum resistance to abrasion.The upper and lower support brackets are cast 304 SS and offer a sturdy platform for connection to motor and discharge pipe. Offers resistance to corrosion and abrasion.The hexagonal pump shaft guarantees effective impeller rotation.A Stainless Steel non-return valve is fitted in the discharge and prevents back flow of water.

4 ST 1 / 7NO. OF IMPELLERS RATED CAPACITY (M3/H) @ HIGHEST EFFICIENCY SERIES NAME


0

50

100

150

200

250

300

350

0 0,3 0,6 0,9 1,2 1,5

HEAD

(m

)

FLOW (m3/h)

PERFORMANCE DATA

MODEL (50Hz)MOTOR POWER

CAPACITY

l/min 0 5 10 15 20 25

kW HP m3/h 0 0.3 0.6 0.9 1.2 1.5

4ST1/13 0.37 0.5

HEAD

(m)

86 78 70 56 42 23

4ST1/19 0.55 0.75 126 110 105 86 60 30

4ST1/26 0.75 1 173 160 141 117 81 39

4ST1/38 1.1 1.5 253 234 208 169 117 52

4ST1/49 1.5 2 325 302 268 219 151 68

4ST1/49

4ST1/38

4ST1/26

4ST1/19

4ST1/13

Ƞ (%)

Eff % 50 40 30 20 10


ITEM No. PART NAME MATERIAL

1 Discharge head AISI304SS

12 Outer Casing AISI304SS

13 Bowl AISI304SS

14 Impeller PPO

15 Diffuser PC

17a Coupling ring PC

17b Motor adapter AISI304SS

21 Cable tube AISI304SS

22a Valve seat AISI304SS

22b Seat assembly PC

23 Valve AISI304SS

25 Strainer AISI304SS

29 Shaft AISI304SS

38a Shaft sleeve AISI304SS

38b Coupling spline AISI304SS

39 Bush bearing PU

44a Washer AISI304SS

44b Adjusting washer AISI304SS

TECHNICAL DATA

MODEL (50Hz)MOTOR POWER DIMENSIONS & WIGHTS

kW HP LENGTH (mm) N.W kg

4ST1/13 0.37 0.5 382 3.7

4ST1/19 0.55 0.75 481 4.7

4ST1/26 0.75 1 596 5.8

4ST1/38 1.1 1.5 832 8.1

4ST1/49 1.5 2 1052 10.45


4 SD BOREHOLE RANGE (4”)


4 SD BOREHOLE RANGE (4”)

4SD Applications For water supply from boreholes, wells or reservoirs For domestic use, for civil and industrial applications For garden use and irrigation Operating conditions Maximum fluid temperature: up to + 35 ° C Maximum sand content: 0.25% Minimum well diameter: 4” Motor and Pump Single-phase: 220 ~240V/50Hz Three-phase: 380 ~415V/50Hz Solar: 220v-3phase Equipped with start control box or digital auto-control box NEMA dimension standards Curve tolerance according to ISO 9906

Warranty: 1year (according to our general sales conditions).


4 SD 2

-

4 SD 2


4 SD 3

-

4 SD 3


4 SD 4

-

4 SD 4


4 SD 6

-

4 SD 6


4 SD 8

-

4 SD 8


4 SD 10

-

4 SD 10


4 SD 12

-

4 SD 12


4 SD 16

-

4 SD 16



1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”



1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/4”

1 1/2”

1 1/2”

1 1/2”

1 1/2”

1 1/2”

1 1/2”

1 1/2”

1 1/2”

1 1/2”

1 1/2”

1 1/2”

1 1/2”

1 1/2”

1 1/2”

1 1/2”

1 1/2”

1 1/2”



2”

2”

2”

2”

2”

2”

2”

2”

2”

2”

2”

2”

2”

2”

2”


MAXIMUM CABLE LENGTH FROM PUMP TO STARTER

Type kW in(A) 1.5 mm2 2.5 mm2 4 mm2 6 mm2 10 mm2 16 mm2 25 mm2

220V~/50H

0.37 4.2 111 185 295

0.55 4.5 80 133 211 315

0.75 6 58 96 153 229 377

1.1 9 48 79 153 190 316

1.5 10.3 34 57 92 137 228

2.2 14.6 43 68 102 169

380V~/50H

0.37 1.4 768

0.55 2.2 489 811

0.75 2.3 416 691

1.1 3.4 281 467 744

1.5 4.2 219 363 579 862

2.2 5.5 153 254 405 605 997

3 7.9 113 188 300 447 736

4 9.6 89 147 235 350 578 909

5.5 13.6 66 109 174 260 427 671

7.5 17.6 49 81 130 193 319 501 746

INSTALLING A BOREHOLE PUMP AND MOTOR

TECHNICAL DATA


Motor technical dataSingle phase power: 0.37 to 2.2 kW Speed: 2850rpmVoltage: 220 ~ 240V/50Hz Insulation class: B Protection grade: IP 68Highest temperature of Iiquid: 35oCMaximum solid handling: 40g/m3

Motor casing: stainless steelMaximum diameter: Φ 95 mmWith sandproof cover/pressure balance membrane/mechanical seal for high performance. Flange and coupling according to NEMA standard.

TYPEMOTOR POWER

CAP RUNNING DIMENSIONS

Single Phase 220V~/50HZ

kW HP μf AmpsLength (mm)

Weight (kg)

4SDm-0.37 0.37 0.5 20 3.7 314 6.74SDm-0.55 0.55 0.75 25 4.7 329 7.34SDm-0.75 0.75 1.0 35 6.2 344 8.04SDm-l.l 1.1 1.5 45 8.0 399 10.64SDm-l.5 1.5 2.0 55 10.5 424 11.74SDm-2.2 2.2 3.0 60 15 502 15.7

MOTOR DIMENSIONS

MOTOR WIRING

4” OIL FILLED MOTOR 20BAR SINGLE PHASE


PUMP CONTROLLER

MA ANALOGUE CONTROL BOX SINGLE PHASE

Technical dataThis single phase control box is equipped with a capacitor and thermal over-load protector.

Application rangeType of motor: Single phase motorMotor power: 0.37-2.2kWVoltage: 220V ~240VFrequency: 50Hz

Product functionsProvides basic protection against short circuiting and over current.

Operating methodManual control.

Installation environment indexGrade protection: IP44Environment temperature: -25oC to +55oCEnvironment humidity: (20-90)%RH

POWERRUNNING

CAPACITORMCB

kW HP Microfarad (µF) Amp

0.37 0.50 20 80.55 0.75 30 10

0.75 1.00 40 15

1.1 1.50 50 151.5 2.00 65 202.2 3.00 80 25


PUMP CONTROLLER

M521 DIGITAL CONTROL BOX SINGLE PHASE

TECHNICAL DATA

RATED OUTPUT POWER 0.37kW - 2.2kWRATED INPUT VOLTAGE AC220V/50Hz Single PhaseTRIP RESPONSE TIME OF OVER LOAD 5sec - 5minTRIP RESPONSE TIME OF SHORT CIRCUIT 0.1secTRIP RESPONSE TIME OF UNDER / OVER VOLTAGE 5secTRIP RESPONSE TIME OF DRY RUN 6secRECOVERY TIME OF OVER LOAD 30minRECOVERY TIME OF UNDER / OVER VOLTAGE 5minRECOVERY TIME OF DRY RUN 30minTRIP VOLTAGE OF OVER VOLTAGE 110% of rated input voltageTRIP VOLTAGE OF UNDER VOLTAGE 80 of rated input volgage

Product functions • Liquid level control for supply (borehole) and delivery (storage). Enabled for operation, utilising floating level switch / liquid level probe / pressure switch. • Over / under voltage protection with adjustable parameters. • Auto / Manual operation. • Dynamic and interactive LCD display. • Push Button Calibration • Pump Accumulative Running Time Display • Pump Last Five Fault condition Recording • Controller enabled for operation with single phase motor fitted with internal or external capacitor from 0.18 to 2.2kw. Capacitor to be retro fitted for borehole motor use. Refer to capacitor size requirement as per table below.

Application rangeType of motor: Single phase motorMotor power: 0.37-2.2kWVoltage: 220VFrequency: 50Hz

Installation environment indexGrade protection: IP22Environment temperature: -25 ° C to + 55 ° CEnvironment humidity: (20-90)%RH

SINGLE PHASE 3” / 4” OIL FILLED BOREHOLE MOTOR CAPASITOR RATINGS

kW Capacitor (mF)

0.37 20

0.55 25

0.75 35

1.1 45

1.5 55

2.2 75


INSTALLATIONELECTRICAL CONNECTION TO THE POWER SUPPLY:

PROTECTION FUNCTIONSDry run Over load Transient surge Under voltage Over voltage Pump stalled Short circuit

MEANING OF THE ICONS SHOWN ON THE LCD


Motor technical dataThree phase power: 0.37 to 7.5kW Speed: 2850rpmVoltage: 380 ~ 415V/50Hz Insulation class: B Protection grade: IP 68Highest temperature of Iiquid: 35oCMaximum solid handling: 40g/m3


TYPEThree Phase 380V~/50HZ

MOTOR POWER DIMENSIONS

kW HPRUNNING

AMPSLength (mm) Weight (kg)

4SD - 0.37 0.37 0.5 1.5 314 6.74SD - 0.55 0.55 0.75 1.8 329 7.34SD - 0.75 0.75 1.0 2.5 344 84SD - 1.1 1.1 1.5 3.2 379 9.84SD - 1.5 1.5 2.0 4.3 424 11.74SD - 2.2 2.2 3.0 6.0 514 15.74SD - 3 3.0 4.0 8.0 594 19.84SD- 4 4.0 5.5 10.0 698 23.74SD - 5.5 5.5 7.5 13.0 788 284SD - 7.5 7.5 10.0 17.0 908 34

MOTOR DIMENSIONS

4” OIL FILLED MOTOR 20BAR THREE PHASE


SERIAL NO. PART NAME MATERIAL

01 Cable 3 Core/4 Core

EPR

02 Mechanical Seal Ceramic/Carbon

03 Bearing Bush Carbon

04 Upper Housing CI (FG-200)/S.S.30405 Motor Pipe Stainless Steel06 Rotor shaft S.S.42007 Bearing Bush Carbon08 Lower Housing CI (FG-200)09 Thrust Bearing set Carbon/S.S. 42010 Lower Part - 2 CI (FG-200)11 Pressure Cup N.B.R.12 Motor Base S.S.30413 All Hardware S.S.316

MOTOR PARTS

DIMENSIONAL DRAWINGS

TECHNICAL DATA


CSR PERFORMANCE DATA OF THREE PHASE MOTORS (380VOLT/50HZ)

PN

THRUST LOAD UN nN IN IA η (%) COSφ TN TA

(kW) (HP) (N) (V)(min-

1)(A) (A) 50 75 100 50 75 100 (Nm) (Nm)

0.55 0.75 1500 380 2830 1.60 6.00 61 67 67 0.59 0.72 0.80 1.90 3.10

0.75 1 1500 380 2850 2.10 8.90 63 68 70 0.57 0.70 0.79 2.50 4.80

1.1 1.5 3000 380 2820 3.00 13.80 69 72 72 0.59 0.73 0.81 3.80 9.60

1.5 2 3000 380 2840 3.90 18.60 69 72 73 0.59 0.72 0.81 5.00 11.30

2.2 3 4000 380 2815 5.80 28.70 72 75 75 0.58 0.72 0.81 7.60 21.70

3 4 4000 380 2795 8.80 30.60 69 72 70 0.59 0.72 0.83 10.50 21.44

4 5.5 4000 380 2785 10.80 32.30 63 67 70 0.73 0.79 0.83 13.40 21.24

5.5 7.5 4000 380 2785 14.80 50.50 70 73 74 0.75 0.79 0.84 18.93 37.18

7.5 10 4000 380 2850 18.00 61.00 71 72 73 0.99 0.95 0.91 24.60 45.00

PN - Rated OutputUN - Rated VoltagenN - RPMIN - Full Load CurrentIA - Starting Current

TECHNICAL DATA

η - Motor Efficiencycosϕ- Power FactorTN - Full Load TorqueTA - Starting TorqueF[N[ - Axial Thrust Load



PUMP CONTROLLER

General description

The 3 phase pump controller is an electronic control/protector for most pump motors and its operation and installation will be explained in the following pages:

1. Over current/under voltage protection is performed automatically by switching the main supply to the pump motor off.

2. In the event of a power failure or input voltage lower than 160V, the controller will switch off the power to the pump motor in 4 seconds.

3. The unit can also determine water levels in tanks or reservoirs and control the pump according to demand.

Technical features

Rated Voltage: 380V ± 15%Output Power: 4kW (8 amp)Operating Temperature: -10 to +40°CControl Distance: 1kmHumidity: ≤ 90%Height above Sea Level: 2000mProtection function: Time extension feature

DIGITAL STARTER PROTECTOR - 3 PHASE, 380V

OVERLOAD(TIMES)

PROTECTION TIME (SECONDS)

1.3 501.5 302 153 65 1


Operation

1. Water level control: one reservoir/ water tank can be controlled via the wiring connection at the bottom of the controller.

2. Over load protection: At the loss of any one phase, the phase detection CCT will signal the power contactor to drop out and switch the power supply to the pump motor off. Should for any reason the motor draw too much (high) current (see current setting) the over current protection CCT will signal the power contactor to drop out and switch of the power to the motor. This is done automatically in the time set by the installer, see Setting and Adjustments for high current and fast switch off times (anti-time overload protection). The overload LED / light will light up (blink) in the event of a power failure. Also refer to the failure enquiry feature.

3. Short CCT protection: The controller will react the same as in the case of an overload, high current condition occuring and power to the pump motor will be switched off within the same time limit as set by the installer.

4. Over/under Voltage protection: The small LED on the PCB will blink if this function is switched on. The voltage may vary as specified - 380V ± 15%. The controller will self protect within 20 seconds when the voltage drops below 280V.


installation

1. Fit the controller vertically to the appropriate area. Avoid dust, sun light and rain.

2. Connect the input power to the 3 phase input terminal market A,B and C.

3. Connect the pump motor cable wiring to the output terminals also marked A, B and C. They are to the right of the input connections.

4. Connect the water reservoir/tank probe cables to the terminals marked high, med and low at the right bottom of the PC board. Also note the small switch below the green LED, on far right-hand side just above the tank terminals. A selection can be made for the upper or lower tank.

Lower Tank/Cistern:Max water level: Power onMin water level: Power off

Upper Tank / Cistern: Min water level: Power on Max water level: Power off


5. Lack of water: Switch to lower cistern. Should the lower tank lack water, whilst the pump is still running, the pump motor current will be low and the controller will sense this low current or no-load situation as there is no water in the tank and will therefore switch power to the motor off within 10 seconds.

6. Should the pump be in power-on modebut it has been switched off for a no-load fault and the tanks are now full of water,the probes in the tank will signal that the tank is full and the contactor will supply power to the motor. The unit will also do a self test every 30 minutes (adjustable),provided that no-load switch is on.

7. The water full LED will come on as the tank probes signal that the water is at a high level.

8. Reset on the front panel should only be used to get the pump’s motor running again, in the event of the controller switching off, after the installation has gone through a fault finding test.

9. The user may also select water level or pressure control by switching to either function on the small PCB’s second last switch, marked “pressure” and “water”.

10. Switch to upper cistern, pump will not run. Lack of water will send a signal to switch on the power to pump motor.


Settings and adjustments

1. This unit has 10 failure data reports and by pressing the failure enquiry button on the front panel the user can select, with the arrows, any report that will be displayed on the digital current indicator A.

Should a failure light blink, pressing the failure enquiry button will result in the current indicator showing that particular fault condition. Overload will show overload current.

2. Should a phase loss be indicated on the front panel, the user will see the following on the current indicator when pressing the failure enquiry button: 011 - phase A loss 101 - phase B loss 110 - phase C loss 111 - this code with the light on means that the input connections are not wired properly or the pressure mode senses low pressure which causes switch off condition and one has to re-set continuously until the fault has been fixed.


3. The on/off switch on the front panel may also be used to stop the function of the controller or switch the pump motor back on again.

4. The “all complete / enter” button: after running the pump motor normally for60 seconds the user may press the “enter”button mentioned above. This is foundon the PCB above the level connectors.Note that the overload LED on the frontpanel will flicker for 6 seconds and the turn off.

This means that the running and overload current settings with other functions has been memorized and the controller is in the ready state.

5. By selecting “lower or upper tank/cistern”, “pressure or water” the installer/user user will notice that the LED corresponding to that switch will be on if the switch is in the lower position. The LED will go off in the upper position. Also note that the factory default signal to the controller is set on the “upper cistern”.

6. Over-load setting: Switch the controller on and take note of the running current, then press the overload set/confirm (O/L SET/EN) with the LED now ON. Press the up/down arrow button to select or adjust the digital indicator to the value recorded and a bit more, then press the O/L SET/EN button with the LED now off.


7. No-load setting. Start the pump motor and run for 60 seconds with “no load” . The current should be low. Record this value and press the set/confirm (N/L SET/EN) button on the front panel. With the LED above now “on”, select and adjust with the up/down arrow buttons the current setting as displayed on the digital display.

Press the N/L SET/EN button again with the LED off. The value has been recorded and memorized. The no-load current can be set directly as 0.85 times that of the normal operating/running current. The factory default no-load setting is 0.1 amp.

8. No-load reset time. After running the pump motor, switch the “no-load lack water extended set to “on”, located below the red LED. The current digital indicator now shows the no-load reset time in minutes. By adjusting with the “up/down” arrows, select the time required. Then switch to “off”. The time has now been recorded and memorized. Suggested time is 20 minutes as the factory default time is 30 minutes.

9. Over/Under voltage. After running the pump motor, switch the “high/low voltage” switch to “on”. This is located under the yellow LED on the board and the light will be on. This will ensure that

the high/low voltage protection function/protector is ON and will protect as per the specification of 380V ± 15%.


FLOAT LEVEL CONNECTIONS

Tank Filling - upper tank connections:

No loadLack waterExtended time Set0

ON

OFF

High VoltageLow Voltage protection

ON

OFF

Pressure

Water

Upper Tank

Lower Tank

High Med Low

All complete button

When tank is empty there should be an open circuit Low and Med-High, pump will then start.

Not Used

Float Level FSK-1


FAULT FINDING

If the control unit is connected to the water pressure system and the pump motor does not switch on at the minimum pressure, check the following:

1. Ensure that the wiring is done correctly, see diagram.

2. If the wiring is correct and the system still does not operate correctly, remove the wiring and short CCT the terminals H, M and L. Start the pump motor. If the motor runs, it is an indication that the wiring to the pressure system is faulty or the probes are defective. Repeat by shorting and disconnecting to make sure the unit is fine.

No loadLack waterExtended time Set

ON

OFF

High VoltageLow Voltage protection

ON

OFF

Pressure

Water

Upper Tank

Lower Tank

High Med Low

All complete button

Water

Max pressure point

Min pressure point

Loop


PUMP CONTROLLER

DIGITAL STARTER PROTECTOR - 3 PHASE, 380V GENERATION 2


PUMP CONTROLLER

DIGITAL STARTER PROTECTOR - 3 PHASE, 380V GENERATION 2Responsibility The manufacturer is not liable for malfunctioning if the product has not been installed correctly, damaged, modified, run outside the recommended work range or in contrast with other indications given in this manual. The manufacturer declines all responsibility for possible errors in this operation manual, if due to misprints or errors in copying. The manufacturer reserves the right to make any modifications to products that it may consider necessary or useful, without affecting the essential characteristics. Introduction The digital starter protection panel “Generation2” is useful for all application wher control and protect is required for single pumps, managing its turn-on and turn off by different electric installations.Typical usage scenarios include: - Houses - Flats - Holidays houses - Farms - Water supply from wells - Irrigations of greenhouses, gardens, agriculture - Rain water reuse - Industrial plants - Waste water tank / Sewage sink

Technical parameter & features Main features:• Built In function switch applied for water supply by liquid level control through float switch or liquid probe applied for water supply by pressure control through pressure switch and pressure tank applied for drainage by liquid level control through float switch or liquid probe• Automaticly stops the pump in the case of water shortage, protecting it from dry running without installing float switch or liquid probe in the well• Auto / Manual switch• Dynamic LCD displaying pump running state• Push Button Calibration• Pump Accumulative Running Time Displaying• Pump Last Five Fault Record Displaying• RS485 Communication• Starts and stops the pump in accordance with the different liquid level or pressure setting• Protect the pump against many faultsIntelligent Pump Controller model M531 is an easy to use, programmable controlling & protection device for direct start, three phase deep well submersible pump, centrifugal pump, pipeline pump etc with output power from 0.75KW to 7.5KW (1HP-10HP).The model has many operation modes by adopting different electric installations. An important feature that makes the difference between panel and common On/Off pump control box is the probe / sensor free in the well. Our special design makes it a very reliable and sensitive protection against pump dry run without installation probe / sensor in the well.


MAIN TECHNICAL CHARACTERISTIC

Control characteristic double liquid level controlpressure control

Control method Manual / AutoLiquid level control characteristic pulse electrode probe & float switchPressure control characteristic pressure switch (n/c) & pressure tank

MAIN TECHNICAL DATA

Rated output power 0.75-4KW(1HP-5.5HP)5.5-7.5KW (7.5HP-10HP)

Rated input voltage refer to the nameplateTrip response time of over load 5sec-5minTrip response time of open phase < 2 secTrip response time of short circuit < 0.1secTrip response time of under / over voltage < 5secTrip response time of dry run 6secRecovery time of over load 30minRecovery time of under / over voltage 5minRecovery time of dry run 30minTrip voltage of over voltage 115% of the rated input voltageTrip voltage of under voltage 80% of the rated input voltageLiquid level transfer distance ≤1000m

Protection function

Dry runOver loadTransient surgeUnder voltageOver voltageOpen phasePump stalledShort circuit

MAIN INSTALLATION DATA

Working temperature -25℃ -- +55℃Working humidity 20% - 90%RH, no drips concretedDegree of protection IP22Install position VerticalUnit dimensions ( L x W x H) 16 x 8.2 x 22.8 cmUnit weight (net) 1.3kg

RS485 TECHNICAL DATA

Physics Interface RS485 Bus Interface: asynchronism semiduplexBaud rate 1200 bps, 2400 bps, 4800 bpsk, 9600bps

Default: 9600bpsProtocol type MODBUS Protocol (RTU)

TECHNICAL PARAMETS


CONTROLLER COMPONENTS


ICON DESCRIPTIONS


INSTALLATION

Electrical connection to the power supply line and electrical pump

DANGER Electric shock risk Before carrying out any installation or maintenance operation, the M531 should be disconnected from the power supply and one should wait at least 2 minutes before opening the appliance. Never connect AC power to output UV W terminals. Don’t put wire, metal bar filaments etc into the controller. Ensure the motor, controller and power specifications matching. The electrical and hydraulic connections must be carried out by competent, skilled, qualified personnel.


Function switch setting Pump users can set the function switch to meet different application requirements, before setting the function switch, the panel should be disconnected from the power supply, after complete the setting, apply power to the panel and observe the application sign displayed on the LCD conform-ing to the following list.


Parameter Calibration setting & erasingTo achieve best level of protection of the pump, it is essential that parameter calibration must be doneimmediately after successful pump installation or pump maintenance. Setting the parameter calibration Erasing former parameter calibrationWhen pump is reinstalled after maintenance or new pump is installed, user must erase the formerparameter calibration and a new calibration must be done.

Erasing the parameter calibration


Installing liquid probe & float switch



1). Starting condition Liquid level in the water tank is below Lower probe (float switch: Down level) and liquid level in the water well is above Lower probe (float switch: Up level), the panel will run pump;

2). Stop condition Liquid level in the water tank reaches Upper probe (float switch: Up level) or liquid level in the water well is below Lower probe (float switch: Down level); the panel will stop pump running;

3). The probe / sensor free in the water well As the panel has reliable and automatic stop function against pump dry-run (dewatering), if it is used in submersible pump for deep well, pipeline pump or other situations when it is inconvenient to install lower liquid probe in the well, pump users can put terminals 1,2,3 in short circuit, which minimize the troubles and costs. 4). Meaning of the messages & graphic shown on the LCD screen



1). Starting condition There is no pressure in the pipeline or pressure tank, contacting point of pressure switch is ON and liquid level in the water well is above Lower probe (float switch: Up level), the panel will run the pump.

2). Stop condition There is full pressure in the pipeline or pressure tank, contacting point of pressure switch is OFF, the panel will stop pump. Note: pressure switch with N/C (normal close) contacting point: no pressure, contacting point is ON; meet the pressure setting, contacting point is OFF

3). The probe / sensor free in the water well As the panel has reliable and automatic stop function against pump dry-run (dewatering), if it is used in submersible pump for deep well, pipeline pump or other situations when it is inconvenient to install lower liquid probe in the well, pump users can put terminals 1, 2, 3 in short circuit, which minimize the troubles and costs. 4). Meaning of the messages & graphic shown on the LCD screen


1). Starting condition liquid level in the sump reaches Upper probe (float switch A: Up level), the panel will run pump;

2). Stop condition liquid level in the sump is below Lower probe (float switch A: Down level), the panel will stop pump running;

3). Over Flow alarm when pump is draining water, liquid level in the sump is still rising to Overflow probe (float switch B: Up level),the panel will sound the overflow alarm to warn pump user to take further action.

4). Meaning of the messages & graphic shown on the LCD screen


BASIC OPERATION

4.1 Switching to MANUAL modePress the MODE key to switch to manual state, panel is under the manual control state;under manualstate, press the START key to run pump; press the STOP key to stop pump running.

Note: Under manual state, the panel can not receive the signal from liquid level probe or pressure switch.

4.2 Switching to AUTO modePress the MODE key to switch to auto state, panel is under the auto control state;under auto state, panelwill run or stop the pump according to the signal from liquid level probe or pressure switch.

Note: under auto state, if the pump is running and pump user wants to stop pump running compulsory,press the MODE key to switch to manual state and pump stops running.

Note: under auto state, if the input power being cut off and recovery power again, the panel will enteroperation state after 10seconds countdown.

Note: no matter the panel is under auto or manual state, if the input power being cut off and recoverypower again, the panel will resume its operation state as the operation state before power being cut off.

4.3 Pump protectionDuring pump running, if dry run, over load, under voltage, over voltage etc failures happened, the panelwill immediately shut down the pump running and automatically execute a check for restarting conditionsafter a built in time delay has elapsed. The panel will not recover automatically until all the abnormalsituation(s) have been cleared.If pump stalled, open phase etc serious failures happened, pump user must check the pump and motorimmediately and repair the pump.

4.4 Pump last five failure record displayingThe panel can memorize the last five failures of pump, so it is very convenient for the pump users toanalyse the pump running conditions.

Displaying the pump last five failure record- Press the MODE key to switch to manual state, make sure the pump is not running and LCD screen displaying:

- Hold pressing STOP key and press MODE key, the panel makes a “Di” sound, the panel displays pump failure record.

- Press STOP key to quit the failure record displaying;


4.5 Pump accumulative running time displayingThe panel1 can memorize how many hours of pump running, so it is very convenient for the pump users toanalyse the pump running conditions and do maintenance

Displaying the pump accumulative running time- Press the MODE key to switch to manual state, make sure the pump not running and LCD screen displaying:

- Hold pressing button and press STOP key, the panel makes a “Di” sound, the panel displays pump failure record. - Press STOP key to quit the accumulative running time displaying.

TR

OU

BL

E S

HO

OT

ING

GU

IDE

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TYPEMOTOR POW-

ERRUNNING DIMENSIONS

Single Phase 220V~/50HZ

kW HP AmpsLength (mm)

Weight (kg)

4SD-0.75 0.75 1.0 4.0 344 8.04SD-1.5 1.5 2.0 8.6 424 11.74SD-2.2 2.2 3.0 11.3 344 8.04SD-4.0 4 5.5 18.0 698 23.74SD-5.5 5.5 7.5 24.0 788 28

MOTOR DIMENSIONS

MOTOR WIRING

4” OIL FILLED MOTOR 220V 3PHASE - SOLAR APPLICATION

Note: These motors make use of our AC-DC inverters For more information go to the Solar Inverter AC-DC Catalogue (Solar Products)

MOTOR TECHNICAL DATASingle phase power: 0.75 to 5.5 kW Speed: 2850rpmVoltage: 220 3 phase Insulation class: B Protection grade: IP 68Highest temperature of Iiquid: 35oCMaximum solid handling: 40g/m3



SERIAL NO. PART NAME MATERIAL

01 Cable 3 Core/4 Core

EPR

02 Mechanical Seal Ceramic/Carbon

03 Bearing Bush Carbon

04 Upper Housing CI (FG-200)/S.S.30405 Motor Pipe Stainless Steel06 Rotor shaft S.S.42007 Bearing Bush Carbon08 Lower Housing CI (FG-200)09 Thrust Bearing set Carbon/S.S. 42010 Lower Part - 2 CI (FG-200)11 Pressure Cup N.B.R.12 Motor Base S.S.30413 All Hardware S.S.316

MOTOR PARTS

DIMENSIONAL DRAWINGS

TECHNICAL DATA


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Documents

3 & 4 Borehole Product Rangegatorpumps.co.za/wp-content/uploads/2018/11/A-34-Borehole-Pump-Range-2018.pdfconnection to motor and discharge pipe. Offers resistance to corrosion and